Selective Dosing Module Control System

ABSTRACT

Systems and methods to selectively control plurality of dosing modules may include receiving data indicative of an exhaust flow rate. An amount of reductant to be dosed may be determined based, at least in part, on the data indicative of the exhaust flow rate. A decomposition delay time may also be determined and a first dosing module and a second dosing module may be selectively activated. The first dosing module may be selectively activated at a first time and the second dosing module is selectively activated at a second time. The second time is based on the first time and the determined decomposition delay time.

TECHNICAL FIELD

The present application relates generally to the field of fluid deliverysystems for an exhaust system. More specifically, the presentapplication relates to fluid delivery systems for selective catalyticreduction (SCR) systems.

BACKGROUND

For internal combustion engines, such as diesel engines, nitrogen oxide(NO_(x)) compounds may be emitted in the exhaust. To reduce NO_(x)emissions, a SCR process may be implemented to convert the NO_(x)compounds into more neutral compounds, such as diatomic nitrogen, water,or carbon dioxide, with the aid of a catalyst and a reductant. Thecatalyst may be included in a catalyst chamber of an exhaust system,such as that of a vehicle or power generation unit. A reductant, such asanhydrous ammonia, aqueous ammonia, or urea is typically introduced intothe exhaust gas flow prior to the catalyst chamber. To introduce thereductant into the exhaust gas flow for the SCR process, an SCR systemmay dose or otherwise introduce the reductant through a dosing modulethat vaporizes or sprays the reductant into an exhaust pipe of theexhaust system up-stream of the catalyst chamber.

SUMMARY

One implementation relates to a system for selectively dosing reductantinto an exhaust system. The system includes a first dosing module, asecond dosing module, and a controller. The controller is configured toreceive data indicative of an exhaust flow rate, determine an amount ofreductant based, at least in part, on the data indicative of the exhaustflow rate, and determine a decomposition delay time. The controller isfurther configured to selectively activate the first dosing module at afirst time and selectively activate the second dosing module at a secondtime. The second time being based on the first time and thedecomposition delay time.

Another implementation relates to a method for selectively dosingreductant into an exhaust system. The method includes receiving dataindicative of an exhaust flow rate, determining an amount of reductantbased, at least in part, on the data indicative of the exhaust flowrate, and determining a decomposition delay time. The method furtherincludes selectively activating a first dosing module at a first timeand selectively activating a second dosing module at a second time. Thesecond time being based on the first time and the decomposition delaytime.

Yet a further implementation relates to a non-transitorycomputer-readable medium storing instructions that, when executed by oneor more processors, cause the one or more processors perform severaloperations. The operations include receiving data indicative of anexhaust flow rate, determining an amount of reductant based, at least inpart, on the data indicative of the exhaust flow rate, and determining adecomposition delay time. The operations further include selectivelyactivating a first dosing module at a first time and selectivelyactivating a second dosing module at a second time. The second timebeing based on the first time and the decomposition delay time.

These and other features of the implementations described herein,together with the organization and manner of operation thereof, willbecome apparent from the following detailed description when taken inconjunction with the accompanying drawings, wherein like elements havelike numerals throughout the several drawings described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features,aspects, and advantages of the disclosure will become apparent from thedescription, the drawings, and the claims, in which:

FIG. 1 is a block schematic diagram of an example selective catalyticreduction system having an example reductant delivery system for anexhaust system;

FIG. 2 is a front elevation view of an example reductant delivery systemhaving two dosing modules for a decomposition chamber;

FIG. 3 is a front elevation view of another example reductant deliverysystem having three angularly offset dosing modules for a decompositionchamber;

FIG. 4 is a perspective view of another example reductant deliverysystem having two axially aligned dosing modules for a decompositionchamber;

FIG. 5A is a graph of the timing of dosing by two dosing modules havinga first time delay with the dosing overlapping;

FIG. 5B is a graph of the timing of dosing by two dosing modules havinga second time delay with the dosing not overlapping;

FIG. 5C is a graph of the timing of dosing by two dosing modules havinga third time delay with the dosing of a first dosing module ending whenthe dosing of a second dosing module begins;

FIG. 6 is a flow diagram of an example process for a controller tocontrol the dosing of reductant into an exhaust system using pluralityof dosing modules;

FIG. 7 is a graph of the dosing of reductant by two dosing modules overseveral operational speeds over a one second time period;

FIG. 8A is a graph of the alternating dosing of reductant by two dosingmodules at a first operational speed over a two second time period;

FIG. 8B is a graph of the alternating dosing of reductant by two dosingmodules at another operational speed over a two second time period;

FIG. 8C is a graph of the alternating dosing of reductant by two dosingmodules at yet another operational speed over a two second time period;

FIG. 8D is a graph of the alternating dosing of reductant by two dosingmodules at still yet another operational speed over a two second timeperiod;

FIG. 9 is a flow diagram of another example process for a controller tocontrol the dosing of reductant into an exhaust system using pluralityof dosing modules;

FIG. 10 is a graph of the dosing of reductant by two dosing modules overseveral operational speeds over a one second time period;

FIG. 11A is a graph of the alternating dosing of reductant by two dosingmodules at a first operational speed over a two second time period;

FIG. 11B is a graph of the alternating dosing of reductant by two dosingmodules at another operational speed over a two second time period;

FIG. 11C is a graph of the alternating dosing of reductant by two dosingmodules at yet another operational speed over a two second time period;and

FIG. 11D is a graph of the alternating dosing of reductant by two dosingmodules at still yet another operational speed over a two second timeperiod.

It will be recognized that some or all of the figures are schematicrepresentations for purposes of illustration. The figures are providedfor the purpose of illustrating one or more implementations with theexplicit understanding that they will not be used to limit the scope orthe meaning of the claims.

DETAILED DESCRIPTION I. Overview

In some instances, large amounts of horsepower provided by an internalcombustion engine, such as a diesel engine, may be needed or desired,such as, for example very large trucks, mining equipment, locomotives,etc. To meet such a need, large internal combustion engines, such asdiesel engines, may be developed. However, as engine size and powerincrease, the amount of nitrogen oxide (NO_(x)) compounds produced bysuch engines may also be increased. The NO_(x) compounds may be emittedinto the exhaust. To reduce NO_(x) emissions, a SCR process may beimplemented to convert the NO_(x) compounds into more neutral compounds,such as diatomic nitrogen, water, or carbon dioxide, with the aid of acatalyst and a reductant. The catalyst may be included in a catalystchamber of an exhaust system. A reductant, such as anhydrous ammonia,aqueous ammonia, or urea is typically introduced into the exhaust gasflow prior to the catalyst chamber. However, as engine size increases,the amount of reductant needed to reduce the NO_(x) compounds similarlyincreases. Accordingly, large amounts of reductant may need to beintroduced into an exhaust system to effectively reduce the NO_(x)compounds. In some implementations, the rate at which the reductant isdosed into the exhaust system may be increased. However, some dosingmodules may have a maximum dosing rate capability that may not meet theneeded amount of reductant.

In some implementations, a system may selectively control the dosing ofreductants from multiple dosing modules in a system, either staged inseries or located in a single decomposition chamber, to remove NO_(x)compounds from exhaust gasses. The system may utilize a process thatinvolves the selective use of two or more dosing modules to dosereductants into a decomposition chamber to maximize the effectiveness ofthe dosing to remove NO_(x) compounds from the exhaust gas stream. Thesystem may control two or more dosing modules in the same system, eitherlocated in the same decomposition chamber dosing reductant or dosing inseries within a system. The timing and selection of the dosing of thereductant may be determined by control logic of a controller to maximizethe efficiency of the dosing, maximize the effective use of thereductant, minimize potential negative factors from two or more dosingmodules dosing in the same chamber or system (such as depositformation), and/or overdosing.

The process may permit the dosing of reductant at various intervals incoordination between two or more dosing modules for dosing reductant inthe same decomposition chamber or within the same system. The processmay allow the dosing of reductant to be controlled based on an exhaustflow rate by selectively controlling the dosing of each dosing moduleinto the exhaust gas stream.

In some implementations, the dosing modules may each dose a certainamount of reductant simultaneously over a period of time to meet thedesired amount of reductant. That is, over a given period, such as onesecond, each dosing module of the plurality of dosing modules may dosereductant into the exhaust system for a predetermined period of timeover the given period, such as 100 milliseconds (ms), such that thetotal amount of reductant dosed by the dosing modules meets the neededamount of reductant. In some implementations, two, three, four, or moredosing modules may be used.

In other implementations, the dosing modules may dose at different timesbased on a delay time between each dosing module. That is, over a givenperiod, such as one second, a first dosing module of the plurality ofdosing modules may dose reductant into the exhaust system for apredetermined period of time over the given period, such as 100 ms. Asecond dosing module of the plurality of dosing modules may dosereductant into the exhaust system for a predetermined period of timeover the given period, such as 100 ms. The dosing by the first dosingmodule and the second dosing module may be offset by a time delay. Thepredetermined period of time for the first dosing module and the secondmodule may be determined such that the total amount of reductant dosedby the dosing modules meets the needed amount of reductant. In someimplementations, two, three, four, or more dosing modules may be used.The time delay between modules may be determined such that the dosing bythe several modules is substantially evenly spaced over the givenperiod.

In still further implementations, a first dosing module may be utilizedto perform the dosing until the needed amount of reductant exceeds thefirst dosing module's maximum amount that can be dosed in a givenperiod. A second dosing module may then be used to provide theadditional reductant up to the needed amount of reductant. In someimplementations, two, three, four, or more dosing modules may be used.Thus, if the needed amount of reductant exceeds the maximum amount thatcan be provided by the first and second dosing modules, a third dosingmodule or more may be used to provide the additional reductant.

In some implementations, the dosing modules may cycle in sequencing suchthat the duty cycle for each dosing module of plurality of dosingmodules is substantially the same over N operating cycles, where N isthe number of dosing modules.

While the foregoing has given an overview of controlling multiple dosingmodules, following below are more detailed descriptions of variousconcepts related to, and implementations of, methods, apparatuses, andsystems for introducing a reductant to an exhaust system using pluralityof dosing modules. The various concepts introduced above and discussedin greater detail below may be implemented in any of numerous ways, asthe described concepts are not limited to any particular manner ofimplementation. Examples of specific implementations and applicationsare provided primarily for illustrative purposes.

II. Overview of Selective Catalytic Reduction System

FIG. 1 depicts an selective catalytic reduction system 100 having anexample reductant delivery system 110 for an exhaust system 190. Theselective catalytic reduction system 100 includes a diesel particulatefilter (DPF) 102, the reductant delivery system 110, a decompositionchamber or reactor 104, and a SCR catalyst 106.

The DPF 102 is configured to remove particulate matter, such as soot,from exhaust gas flowing (indicated by arrow 192) in the exhaust system190. The DPF 102 includes an inlet, where the exhaust gas is received,and an outlet, where the exhaust gas exits after having particulatematter substantially filtered from the exhaust gas and/or converting theparticulate matter into carbon dioxide.

The decomposition chamber 104 is configured to convert a reductant, suchas urea, aqueous ammonia, or diesel exhaust fluid (DEF) into ammonia. Aswill be described in greater detail herein, the decomposition chamber104 includes a reductant delivery system 110 having a plurality ofdosing modules 112 configured to dose the reductant into thedecomposition chamber 104. In some implementations, the urea, aqueousammonia, DEF is injected upstream of the SCR catalyst 106. The reductantdroplets then undergo the processes of evaporation, thermolysis, andhydrolysis to form gaseous ammonia within the exhaust system 190. Thedecomposition chamber 104 includes an inlet in fluid communication withthe DPF 102 to receive the exhaust gas containing NO_(x) emissions andan outlet for the exhaust gas, NO_(x) emissions, ammonia, and/orremaining reductant to flow to the SCR catalyst 106.

The SCR catalyst 106 is configured to assist in the reduction of NO_(x)emissions by accelerating a NO_(x) reduction process between the ammoniaand the NO_(x) of the exhaust gas into diatomic nitrogen, water, and/orcarbon dioxide. The SCR catalyst 106 includes inlet in fluidcommunication with the decomposition chamber 104 from which exhaust gasand reductant is received and an outlet.

The exhaust system 190 may further include a diesel oxidation catalyst(DOC) in fluid communication with the exhaust system 190 (e.g.,downstream of the SCR catalyst 106, or upstream of the DPF 102) tooxidize hydrocarbons and carbon monoxide in the exhaust gas.

As noted above, the decomposition chamber 104 includes a plurality ofdosing modules 112 mounted to the decomposition chamber 104 such thatthe plurality of dosing modules 112 may dose a reductant, such as urea,aqueous ammonia, or DEF, into the exhaust gases flowing in the exhaustsystem 190. The plurality of dosing modules 112 may each include aninsulator 114 interposed between the a portion of the dosing module 112and the portion of the decomposition chamber 104 to which the dosingmodule 112 is mounted. The plurality of dosing modules 112 are fluidlycoupled to one or more reductant sources 116. In some implementations,each dosing module 112 may be fluidly coupled to a correspondingreductant source 112 or the plurality of dosing module 112 may becoupled to the same reductant source 116. In some implementations, apump (not shown) may be used to pressurize the reductant source 116 fordelivery to the dosing modules 112.

The plurality of dosing modules 112 are also electrically orcommunicatively coupled to a controller 120. The controller 120 isconfigured to control each dosing module 112, as will be described ingreater detail herein. The controller 120 may include a microprocessor,an application-specific integrated circuit (ASIC), a field-programmablegate array (FPGA), etc., or combinations thereof. The controller 120 mayinclude memory which may include, but is not limited to, electronic,optical, magnetic, or any other storage or transmission device capableof providing a processor, ASIC, FPGA, etc. with program instructions.The memory may include a memory chip, Electrically Erasable ProgrammableRead-Only Memory (EEPROM), erasable programmable read only memory(EPROM), flash memory, or any other suitable memory from which thecontroller 120 can read instructions. The instructions may include codefrom any suitable programming language.

III. Example Configurations for Reductant Delivery Systems

FIG. 2 depicts an example reductant delivery system 210 for adecomposition chamber 200 having two dosing modules 212 mounted to thedecomposition chamber 200. The dosing modules 212 may each include aninsulator 214 interposed between a portion of the dosing module 212 andthe portion of the decomposition chamber 200 to which the dosing module212 is mounted. In the present example, the dosing modules 212 aremounted to the decomposition chamber 200 at substantially the samelongitudinal axial position, but at different angular positions aboutthe decomposition chamber 200. As shown in FIG. 2, the dosing modules212 are positioned opposite each other on a left side 202 and a rightside 204 of the decomposition chamber 200. In other implementations, thedosing modules 212 may be at other angular positions relative to eachother. For example, a dosing module 212 may be located on the left side202 at 60 degrees from a vertical axis towards the top of thedecomposition chamber 200 and the other dosing module 212 may be locatedon the right side 204 at 60 degrees from the vertical axis towards thetop of the decomposition chamber 200, thereby forming a substantial Vshape orientation relative to each other. Of course, any otherpositioning of the dosing modules 212 about the decomposition chamber200 may be used.

FIG. 3 depicts another example reductant delivery system 310 for adecomposition chamber 300 having three dosing modules 312 mounted to thedecomposition chamber 300. The dosing modules 312 may each include aninsulator 314 interposed between a portion of the dosing module 312 andthe portion of the decomposition chamber 300 to which the dosing module312 is mounted. In the present example, the dosing modules 312 aremounted to the decomposition chamber 300 at substantially the samelongitudinal axial position, but at different angular positions aboutthe decomposition chamber 300. As shown in FIG. 3, the dosing modules312 are equally spaced about the decomposition chamber 300, such as at120 degree intervals with a dosing module 312 located at a top 306 ofthe decomposition chamber 300. Of course, the dosing modules 312 may bepositioned at other angular positions relative to each other.Furthermore, it should be understood that more than three dosing modules312 may be used. For example, four dosing modules, five dosing modules,etc.

FIG. 4 depicts another example reductant delivery system 410 for adecomposition chamber 400 having two axially aligned dosing modules 412mounted to the decomposition chamber 400. The dosing modules 412 mayeach include an insulator 414 interposed between a portion of the dosingmodule 412 and the portion of the decomposition chamber 400 to which thedosing module 412 is mounted. In the present example, the dosing modules412 are mounted to the decomposition chamber 400 at substantially thesame angular position, but at different longitudinal axial locations. Itshould be understood that more than three dosing modules 312 may beused. For example, four dosing modules, five dosing modules, etc.

In some implementations, the dosing modules described herein may be bothaxially offset and angularly offset (i.e., a combination of FIGS. 2-3and FIG. 4). Furthermore, it should be understood that any number ofdosing modules may be used. For example, four dosing modules, fivedosing modules, etc.

IV. Example Processes for Selective Control of Dosing Modules

As noted above, plurality of dosing modules, such as dosing modules 112of FIG. 1, are electrically or communicatively coupled to a controller,such as controller 120 of FIG. 1. Described in greater detail herein areprocesses that may be implemented by the controller to control thedosing by the plurality of dosing modules.

FIGS. 5A-5C depict various dosing scenarios for two dosing modules. Itshould be understood that the following scenarios may be further appliedto three, four, five or more dosing modules. FIG. 5A depicts a graph 500of the timing of dosing by two dosing modules having a first time delay510 with the dosing overlapping. As shown, a first dosing module dosesfor first time period 512. The second dosing module doses for a secondtime period 514, which is offset by the first time delay 510. Asillustrated, the second dosing module starts to dose prior to the firstdosing module ceasing dosing. Thus, the first time period 512 of thedosing by the first dosing module and the second time period 514 of thedosing by the second dosing module overlap.

FIG. 5B depicts the graph 500 of the timing of dosing by two dosingmodules having a second time delay 520 with the dosing not overlapping.As shown, a first dosing module doses for first time period 522. Thesecond dosing module doses for a second time period 524, which is offsetby the second time delay 520. As illustrated, the second dosing modulestarts to dose after the first dosing module has ceased dosing. Thus,the first time period 522 of the dosing by the first dosing module andthe second time period 524 of the dosing by the second dosing module donot overlap.

FIG. 5C depicts the graph 500 of the timing of dosing by two dosingmodules having a third time delay 530 with the dosing of a first dosingmodule ending when the dosing of a second dosing module begins. Asshown, a first dosing module doses for first time period 532. The seconddosing module doses for a second time period 534, which is offset by thesecond time delay 530. As illustrated, the second dosing module startsto dose as the first dosing module ceases dosing. Thus, the first timeperiod 532 of the dosing by the first dosing module and the second timeperiod 534 of the dosing by the second dosing module “abut.”

FIG. 6 is a flow diagram of an example process 600 for a controller tocontrol the dosing of reductant into an exhaust system using pluralityof dosing modules. At 602, the process 600 includes receiving dataindicative of an exhaust flow rate. The data indicative of the exhaustflow rate may include and/or be determined based on an engine speedselection, a flow velocity measurement, or a combination of calculatedand measured components including air mass flow, fuel flow, temperature,pressure, rate of change of those, or a combination of all or some ofthose, etc. The data indicative of the exhaust flow rate may becommunicated from one or more sensors.

At 604, an amount of reductant may be determined by a controller. Theamount of reductant may be determined based, at least in part, on thedata indicative of the exhaust flow rate. For example, amount ofreductant may be determined based on an engine speed selection (e.g., anoperating speed of the engine at known speed-load points) or engineoperating parameters. In other implementations, the amount of reductantmay be determined based on other data, either in addition or instead ofthe data indicative of the exhaust flow rate. The amount of reductantmay be based on a dosing rate of one of more dosing modules, an exhaustgas temperature, etc.

At 606, a decomposition delay time may be determined by a controller.The decomposition delay time is a delay between dosing modules, such asa first dosing module and a second dosing module. In someimplementations, the decomposition delay time may be determined as afunction of a dosing rate of the dosing modules, an exhaust gastemperature, an exhaust flow rate, an evaporative cooling rate for thereductant, a heat transfer environment, a current temperature of thesystem, and/or may be empirically determined for various conditions(e.g., for various engine speed-load points, exhaust flow rate andtemperatures, etc.), and measured and calculated parameters. Thedecomposition delay time may be determined such that decomposition mayoccur while avoiding deposits and providing NH₃ to the catalyst as closeto the dosing time as possible. If a delay time is too short, depositsmay form within the exhaust system. If the delay time is too long, thesystem may not be able to dose the amount of reductant needed. In someimplementations, the decomposition delay time may be in 100 msintervals. In some implementations, the decomposition delay time todosing module pulse frequency may be 1/10^(th) to 6/10^(ths) (e.g., for1 Hz dosing module pulses, the decomposition delay time may be between100 ms and 600 ms). Of course, other delay times may be used.

In still further implementations, the decomposition delay time may bedetermined for plurality of dosing modules. For example, in a systemwith three dosing modules, the decomposition delay time may bedetermined between dosing for a first module and a second module andbetween dosing for the second module and a third module.

At 608, a first dosing module is selectively activated by a controllerand, at 610, a second dosing module is selectively activated by acontroller. The first dosing module may be selectively activated at afirst time and the second dosing module is selectively activated at asecond time, with the second time being determined based on the firsttime and the determined decomposition delay time. That is, thedetermined decomposition delay time is utilized to time offset theactivation of the second dosing module relative to the first dosingmodule.

In some implementations, the selective activation of the first dosingmodule and the second module may include selectively activating thesecond dosing module at a second time while the first dosing module isactivated (e.g., overlapping, such as that shown in FIG. 5A). In furtherimplementations, the selective activation of the first dosing module andthe second module may include selectively activating the second dosingmodule after the first dosing module is deactivated (e.g., notoverlapping, such as that shown in FIG. 5B). In still furtherimplementations, the selective activation of the first dosing module andthe second module may include selectively activating the second dosingmodule when the first dosing module is deactivated (e.g., abutting, suchas that shown in FIG. 5C).

In some implementations, a third dosing module may be selectivelyactivated by a controller at 612. The selective activation of the thirddosing module may be at a third time that is based on the first time,the second time, and the decomposition delay time. Additional dosingmodules may be activated as needed in a similar process by a controller.In still further implementations, such as if a dosing module fails or isotherwise rendered inoperable, the controller may be configured to keepdosing with any remaining dosing modules such that reductant is stilldosed, but at a lesser level. Thus, for example, a vehicle incorporatingsuch an engine may “limp home,” such as to a location where theinoperable dosing module may be repaired and/or replaced.

FIG. 7 is a graph 700 of the dosing of reductant by two dosing modulesover several operational engine speeds over a one second time period. Ata first operational speed, a first dosing module doses reductant for afirst period of time 702. After a first decomposition delay time, suchas 500 ms as shown, a second dosing module doses reductant for a secondperiod of time 704. The first dosing module and the second dosing modulemay continue to alternate dosing based on the first decomposition delay.In the example shown, the dosing by the first dosing module for thefirst period of time 702 and the dosing by the second dosing module forthe second period of time 704 do not overlap.

At a second operational speed, the first dosing module doses reductantfor a first period of time 712. The second dosing module doses reductantfor a second period of time 714 after the decomposition delay time of500 ms. The first dosing module and the second dosing module maycontinue to alternate dosing based on the decomposition delay time. At athird operational speed, the first dosing module doses reductant for afirst period of time 722. The second dosing module doses reductant for asecond period of time 724 after the decomposition delay time of 500 ms.The first dosing module and the second dosing module may continue toalternate dosing based on the decomposition delay time. At a fourthoperational speed, the first dosing module doses reductant for a firstperiod of time 732. The second dosing module doses reductant for asecond period of time 734 after the decomposition delay time of 500 ms.The first dosing module and the second dosing module may continue toalternate dosing based on the decomposition delay time.

At a fifth operational speed, the first dosing module doses reductantfor a first period of time 742. After a second decomposition delay time,such as approximately 480 ms as shown, the second dosing module dosesreductant for a second period of time 744. In the present example, thesecond decomposition delay time is reduced based on the second dosingmodule needing to be active for longer than the 500 ms time to meet theamount of reductant needed at the fifth operational speed. Thus, in theexample shown, the dosing by the first dosing module for the firstperiod of time 742 and the dosing by the second dosing module for thesecond period of time 744 overlap. The first dosing module and thesecond dosing module may continue to alternate dosing based on thesecond decomposition delay time.

At a sixth operational speed, the first dosing module doses reductantfor a first period of time 752. After a third decomposition delay time,such as approximately 300 ms as shown, the second dosing module dosesreductant for a second period of time 754. The first dosing module andthe second dosing module may continue to alternate dosing based on thethird decomposition delay time. At a seventh operational speed, thefirst dosing module doses reductant for a first period of time 762.After a fourth decomposition delay time, such as approximately 120 ms asshown, the second dosing module doses reductant for a second period oftime 764. The first dosing module and the second dosing module maycontinue to alternate dosing based on the fourth decomposition delaytime.

FIGS. 8A-8D depict such alternating dosing of the first dosing moduleand the second dosing module over a time period of two seconds. FIG. 8Adepicts a graph 800 of the alternating dosing of reductant by two dosingmodules at a first operational speed over a two second time period. FIG.8B depicts a graph 810 of the alternating dosing of reductant by twodosing modules at another operational speed over a two second timeperiod. FIG. 8C depicts a graph 820 of the alternating dosing ofreductant by two dosing modules at yet another operational speed over atwo second time period. FIG. 8D depicts a graph 830 of the alternatingdosing of reductant by two dosing modules at still yet anotheroperational speed over a two second time period.

FIG. 9 is a flow diagram of an example process 900 for a controller tocontrol the dosing of reductant into an exhaust system using pluralityof dosing modules. At 902, the process 900 includes receiving dataindicative of an exhaust flow rate. The data indicative of the exhaustflow rate may include and/or be determined based on an engine speedselection, a flow velocity measurement, or a combination of calculatedand measured components including air mass flow, fuel flow, temperature,pressure, rate of change of these parameters, or a combination of all orsome of these parameters, etc. The data indicative of the exhaust flowrate may be communicated from one or more sensors.

At 904, an amount of reductant may be determined by a controller. Theamount of reductant may be determined based, at least in part, on thedata indicative of the exhaust flow rate. For example, amount ofreductant may be determined based on an engine speed selection (e.g., anoperating speed of the engine at known speed-load points) or engineoperating parameters. In other implementations, the amount of reductantmay be determined based on other data, either in addition or instead ofthe data indicative of the exhaust flow rate. The amount of reductantmay be based on a dosing rate of one of more dosing modules, an exhaustgas temperature, etc.

At 906, a first dosing module and a second dosing module are selectivelyactivated by a controller. In some implementations, the first dosingmodule may be selectively activated to provide the amount of reductantfor a first time period. The second dosing module may be selectivelyactivated to provide the amount of reductant for a second time period.Thus, the first dosing module and the second dosing module mayalternatingly provide the amount of reductant over the first time periodand the second time period. In some instances, such as when the firstdosing module may, by itself, not be able to meet the amount ofreductant, the second dosing module may be selectively activated withthe first dosing module for a period of time to supplement the dosingprovided by the first dosing module. At 908, in some implementations, athird dosing module may be selectively activated by a controller. Theselective activation of the third dosing module may be at a third timethat is based on the first time, the second time, and the decompositiondelay time. Additional dosing modules may be activated as needed in asimilar process by a controller.

FIG. 10 is a graph 1000 of the dosing of reductant by two dosing modulesover several operational engine speeds over a one second time period. Ata first operational speed, a first dosing module doses reductant for afirst period of time 1002. At a second operational speed, the firstdosing module doses reductant for a second period of time 1012. At athird operational speed, the first dosing module doses reductant for athird period of time 1022. At a fourth operational speed, the firstdosing module doses reductant for a fourth period of time 1032.

At a fifth operational speed, the first dosing module doses reductantfor a fifth period of time 1042, which is for the entire one secondperiod of time. The second dosing module may be selectively activated todose reductant for a second period of time 1044 to supplement the dosingby the first dosing module. The first dosing module and the seconddosing module may both be selectively activated at the same time or, insome implementations, the selective activation of the second dosingmodule may be offset by a time delay. At a sixth operational speed, thefirst dosing module doses reductant for the fifth period of time 1042.The second dosing module may be selectively activated to dose reductantfor a second period of time 1054 to supplement the dosing by the firstdosing module. The first dosing module and the second dosing module mayboth be selectively activated at the same time or, in someimplementations, the selective activation of the second dosing modulemay be offset by a time delay. At a seventh operational speed, the firstdosing module doses reductant for the fifth period of time 1042. Thesecond dosing module may be selectively activated to dose reductant fora third period of time 1064 to supplement the dosing by the first dosingmodule. The first dosing module and the second dosing module may both beselectively activated at the same time or, in some implementations, theselective activation of the second dosing module may be offset by a timedelay.

FIGS. 11A-11D depict alternating dosing by the first dosing module andthe second dosing module over a time period of two seconds. FIG. 11Adepicts a graph 1100 of the alternating dosing of reductant by twodosing modules at a first operational speed over a two second timeperiod. FIG. 11B depicts a graph 1110 of the alternating dosing ofreductant by two dosing modules at another operational speed over a twosecond time period. FIG. 11C depicts a graph 1120 of the alternatingdosing of reductant by two dosing modules at yet another operationalspeed over a two second time period. FIG. 11D depicts a graph 1130 ofthe alternating dosing of reductant by two dosing modules at still yetanother operational speed over a two second time period.

Implementations of the subject matter and the operations described inthis specification can be implemented in digital electronic circuitry,or in computer software embodied on a tangible medium, firmware, orhardware, including the structures disclosed in this specification andtheir structural equivalents, or in combinations of one or more of them.The subject matter described in this specification can be implemented asone or more computer programs, i.e., one or more modules of computerprogram instructions, encoded on one or more computer storage media forexecution by, or to control the operation of, data processing apparatus.Alternatively or in addition, the program instructions can be encoded onan artificially generated propagated signal, e.g., a machine-generatedelectrical, optical, or electromagnetic signal that is generated toencode information for transmission to suitable receiver apparatus forexecution by a data processing apparatus. A computer storage medium canbe, or be included in, a computer-readable storage device, acomputer-readable storage substrate, a random or serial access memoryarray or device, or a combination of one or more of them. Moreover,while a computer storage medium is not a propagated signal, a computerstorage medium can be a source or destination of computer programinstructions encoded in an artificially generated propagated signal. Thecomputer storage medium can also be, or be included in, one or moreseparate components or media (e.g., multiple CDs, disks, flash drives,or other storage devices). Accordingly, the computer storage medium isboth tangible and non-transitory.

The operations described in this specification can be performed by adata processing apparatus on data stored on one or morecomputer-readable storage devices or received from other sources.

The term “controller” encompasses all kinds of apparatus, devices, andmachines for processing data, including by way of example a programmableprocessor, a computer, a system on a chip, or multiple ones, a portionof a programmed processor, or combinations of the foregoing. Theapparatus can include special purpose logic circuitry, e.g., an FPGA oran ASIC. The apparatus can also include, in addition to hardware, codethat creates an execution environment for the computer program inquestion, e.g., code that constitutes processor firmware, a protocolstack, a database management system, an operating system, across-platform runtime environment, a virtual machine, or a combinationof one or more of them. The apparatus and execution environment canrealize various different computing model infrastructures, such asdistributed computing and grid computing infrastructures.

A computer program (also known as a program, software, softwareapplication, script, or code) can be written in any form of programminglanguage, including compiled or interpreted languages, declarative orprocedural languages, and it can be deployed in any form, including as astandalone program or as a module, component, subroutine, object, orother unit suitable for use in a computing environment. A computerprogram may, but need not, correspond to a file in a file system. Aprogram can be stored in a portion of a file that holds other programsor data (e.g., one or more scripts stored in a markup languagedocument), in a single file dedicated to the program in question, or inmultiple coordinated files (e.g., files that store one or more modules,sub programs, or portions of code).

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of what may beclaimed, but rather as descriptions of features specific to particularimplementations. Certain features described in this specification in thecontext of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresdescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations and even initially claimed as such, oneor more features from a claimed combination can in some cases be excisedfrom the combination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, the separation of various systemcomponents in the implementations described above should not beunderstood as requiring such separation in all implementations, and itshould be understood that the described components and systems cangenerally be integrated in a single product or packaged into multipleproducts embodied on tangible media.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims. Additionally, it is noted that limitations in theclaims should not be interpreted as constituting “means plus function”limitations under the United States patent laws in the event that theterm “means” is not used therein.

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two components directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two components orthe two components and any additional intermediate components beingintegrally formed as a single unitary body with one another or with thetwo components or the two components and any additional intermediatecomponents being attached to one another.

The terms “fluidly coupled,” “in fluid communication,” and the like asused herein mean the two components or objects have a pathway formedbetween the two components or objects in which a fluid, such as water,air, gaseous reductant, gaseous ammonia, etc., may flow, either with orwithout intervening components or objects. Examples of fluid couplingsor configurations for enabling fluid communication may include piping,channels, or any other suitable components for enabling the flow of afluid from one component or object to another.

It is important to note that the construction and arrangement of thesystem shown in the various exemplary implementations is illustrativeonly and not restrictive in character. All changes and modificationsthat come within the spirit and/or scope of the describedimplementations are desired to be protected. It should be understoodthat some features may not be necessary and implementations lacking thevarious features may be contemplated as within the scope of theapplication, the scope being defined by the claims that follow. Inreading the claims, it is intended that when words such as “a,” “an,”“at least one,” or “at least one portion” are used there is no intentionto limit the claim to only one item unless specifically stated to thecontrary in the claim. When the language “at least a portion” and/or “aportion” is used the item can include a portion and/or the entire itemunless specifically stated to the contrary.

What is claimed is:
 1. A system for selectively dosing reductant into anexhaust system, the system comprising: a first dosing module; a seconddosing module; and a controller, the controller configured to: receivedata indicative of an exhaust flow rate, determine an amount ofreductant based, at least in part, on the data indicative of the exhaustflow rate, determine a decomposition delay time, selectively activatethe first dosing module at a first time, and selectively activate thesecond dosing module at a second time, the second time based on thefirst time and the decomposition delay time.
 2. The system of claim 1,wherein the reductant is diesel exhaust fluid.
 3. The system of claim 1,wherein the second dosing module is selectively activated while thefirst dosing module is activated.
 4. The system of claim 1, wherein thesecond dosing module is selectively activated after the first dosingmodule is deactivated.
 5. The system of claim 1, wherein the seconddosing module is selectively activated when the first dosing module isselectively deactivated.
 6. The system of claim 1, further comprising: athird dosing module; wherein the controller is further configured toselectively activate the third dosing module at a third time, the thirdtime based on the first time, the second time, and the decompositiondelay time.
 7. The system of claim 1, wherein the first dosing moduleand the second dosing module are mounted such that the first dosingmodule and the second dosing module dose reductant into a decompositionchamber.
 8. The system of claim 7, wherein the first dosing module andthe second dosing module are mounted on opposing sides of thedecomposition chamber.
 9. The system of claim 1, wherein the dataindicative of an exhaust flow rate is an engine speed.
 10. The system ofclaim 1, wherein the controller is configured to selectively activatethe first dosing module at the first time to dose a first amount ofreductant and to selectively activate the second dosing module at thesecond time to dose a second amount of reductant, a sum of the firstamount of reductant and the second amount of reductant approximatelyequaling the determined amount of reductant, wherein the first dosingmodule and the second dosing module optimize a reduction in NO_(x)compounds in the exhaust system.
 11. A method for selectively dosingreductant into an exhaust system, the method comprising: receiving, at acontroller, data indicative of an exhaust flow rate; determining, usingthe controller, an amount of reductant based, at least in part, on thedata indicative of the exhaust flow rate; determining, using thecontroller, a decomposition delay time; selectively activating, usingthe controller, a first dosing module at a first time; and selectivelyactivating, using the controller, a second dosing module at a secondtime, the second time based on the first time and the decompositiondelay time.
 12. The method of claim 11, wherein the reductant is dieselexhaust fluid.
 13. The method of claim 11, further comprising:selectively deactivating, using the controller, the first dosing moduleafter the second dosing module is selectively activated.
 14. The methodof claim 11, further comprising: selectively deactivating, using thecontroller, the first dosing module before the second dosing module isselectively activated.
 15. The method of claim 11, further comprising:selectively deactivating, using the controller, the first dosing modulewhen the second dosing module is selectively activated.
 16. The methodof claim 11, further comprising: selectively activating, using thecontroller, a third dosing module at a third time, the third time basedon the first time, the second time, and the decomposition delay time.17. The method of claim 11, wherein the selectively activating of thefirst dosing module at the first time doses a first amount of reductantand the selectively activating the second dosing module at the secondtime doses a second amount of reductant, a sum of the first amount ofreductant and the second amount of reductant approximately equaling thedetermined amount of reductant, wherein the first dosing module and thesecond dosing module optimize a reduction in NO_(x) compounds in theexhaust system.
 18. A non-transitory computer-readable medium storinginstructions that, when executed by one or more processors, cause theone or more processors perform operations comprising: receiving dataindicative of an exhaust flow rate; determining an amount of reductantbased, at least in part, on the data indicative of the exhaust flowrate; determining a decomposition delay time; selectively activating afirst dosing module at a first time; and selectively activating a seconddosing module at a second time, the second time based on the first timeand the decomposition delay time.
 19. The non-transitorycomputer-readable medium of claim 18 storing instructions that cause theone or more processors to perform operations further comprising:selectively deactivating the first dosing module after the second dosingmodule is selectively activated.
 20. The non-transitorycomputer-readable medium of claim 18 storing instructions that cause theone or more processors to perform operations further comprising:selectively deactivating, using the controller, the first dosing modulebefore the second dosing module is selectively activated.
 21. Thenon-transitory computer-readable medium of claim 18 storing instructionsthat cause the one or more processors to perform operations furthercomprising: selectively deactivating, using the controller, the firstdosing module when the second dosing module is selectively activated.22. The non-transitory computer-readable medium of claim 18 storinginstructions that cause the one or more processors to perform operationsfurther comprising: selectively activating, using the controller, athird dosing module at a third time, the third time based on the firsttime, the second time, and the decomposition delay time.
 23. Thenon-transitory computer-readable medium of claim 18, wherein theoperation to selectively activate the first dosing module at the firsttime doses a first amount of reductant and the operation to selectivelyactivate the second dosing module at the second time doses a secondamount of reductant, a sum of the first amount of reductant and thesecond amount of reductant approximately equaling the determined amountof reductant, wherein the first dosing module and the second dosingmodule optimize a reduction in NO_(x) compounds in the exhaust system.24. The non-transitory computer-readable medium of claim 18 storinginstructions that cause the one or more processors to perform operationsfurther comprising: determining the first dosing module or the seconddosing module is inoperable; and activating a limp home mode, whereinthe limp home mode continues to activate the remaining first dosingmodule or second dosing module.